Breakable two pack carrier and related apparatus and method

ABSTRACT

A readily dividable container carrier includes a first container engaging opening, a second container engaging opening, and a handle structure located between the first container engaging opening and the second container engaging opening. The handle structure includes a first portion located toward the first container engaging opening and a second portion located toward the second container engaging opening, and a separation line between the first portion and the second portion, the separation line formed by a line of weakness along the handle structure. A method and apparatus for applying the carrier are provided.

TECHNICAL FIELD

The present application relates generally to the field of carrier handles utilized in connection with bottles and other containers and, more specifically, to a dividable carrier that is applied to a pair of adjacent containers and then separated along a separation line to produce individual containers with respective, separate carrier handles.

BACKGROUND

Various configurations of container (e.g., bottle) carriers are known. One type of carrier is a neck-type carrier that generally includes neck engaging opening that slides over the container neck and interacts with a rim of the neck to stay in place when a handle portion of the carrier is grasped for lifting and carrying the container. Carriers of this type are known for single containers and two or more containers, in the latter case the carrier having multiple neck engaging openings.

FIGS. 9A and 9B show a prior art two pack carrier 200 formed as a flexible plastic platform unit that has a line of weakness 202 formed along a mid-line of the carrier handle 204. This line of weakness is formed by what is referred to as a skip cut by which the material along the line 202 is partially cut at various depths. Plastic material runs the full length L of the separation line 202 to connect the two halves 206 and 208 of the handle 204. The subject carrier is configured such that despite the presence of the line of weakness 202, the carrier can be applied to a pair of containers (e.g., a pair of 128 ounce juice containers or a pair of gallon milk containers) and the carrier handle 204 can be used to lift and carry the pair of containers. Testing of the subject carrier has shown that roughly thirty pounds of force or more (perpendicular to the line 202) is required to separate the handle 204 along the line 202. In use, the carrier 200 is applied to a pair of containers and used by stocking personnel and the consumer to carry the container pair. Once a consumer reaches his/her destination (e.g., home), the consumer can separate the carrier 200 along the line of weakness 202 by using a scissors or, in some case, by using a substantially shearing force via a tearing operation.

Generally, different machines are adapted to apply different carriers (e.g., a single carrier applicator machine only applies single item carriers to single containers and a two carrier applicator machine only applies two pack carriers to a two bottle set).

It would be desirable to provide a carrier that may be used to facilitate expanded use of an applicator machine (e.g., producing container pairs with a carrier that carries the container pair or producing individual containers each with its own carrier). It would also be desirable to provide a machine that is adapted for producing either such container pairs with a carrier or individual containers each with its own carrier).

SUMMARY

In one aspect, a container carrier for use in being applied to two containers and subsequently divided to provide and individual carrier on each container is provided. The carrier includes a substantially planar flexible platform having a top surface, a bottom surface, an outer perimeter and an inner region. The inner region of the carrier includes a first container engaging opening having an inner perimeter configured for interacting with a first container neck rim, and a second container engaging opening having an inner perimeter configured for interacting with a second container neck rim, the second container engaging opening spaced from the first container engaging opening. A longitudinal axis of the carrier extends through a center of the first container engaging opening and through a center of the second container engaging opening. A handle structure is located between the first container engaging opening and the second container engaging opening. The handle structure includes a central portion, a first outer side portion and a second outer side portion, the first outer side portion extending from the central portion toward the first container engaging opening, and the second outer side portion extending from the central portion toward the second container engaging opening. The central portion includes a separation line formed therein, the separation line extending substantially perpendicular to the longitudinal axis and between a first inner portion and second inner portion that together make up the central portion. The separation line is formed by a region of connectivity between the first inner portion and the second inner portion and a region of disconnectivity between the first inner portion and the second inner portion. When the central portion is separated along the separation line a first single container carrier and second single container carrier are produced, where the first single container carrier includes the first container engaging opening, the first inner portion and the first outer side portion and the first inner portion and first outer side portion make up a handle of the first single container carrier, and where the second single container carrier includes the second container engaging opening, the second inner portion and the second outer side portion and the second inner portion and second outer side portion make up a handle of the second single container carrier.

In the foregoing aspect, the separation line may be configured such that pulling the first inner portion and the second inner portion away from each other with a force of no more than eight pounds along the longitudinal axis causes the central portion to separate along the separation line.

In the foregoing aspect, the separation line may have an overall length, and a length of the region of connectivity may no more than about ten percent, eight percent, five percent or three percent of the overall length.

In the foregoing aspect, the region of connectivity may be defined by first and second connected locations that are spaced apart from each other by a first part of the region of disconnectivity. In such an implementation, the first part of the region of disconnectivity may be an inner part, and the region of disconnectivity may further include a first outer part located to an outer side of the first connected location and a second outer part located to an outer side of the second connected location.

In the foregoing aspect, a width of the region of disconnectivity may be substantially uniform and a width of the region of connectivity may be no more than about ten thousandths of an inch.

In another aspect, a method of applying carriers to containers involves: positioning a container carrier at a location above first and second adjacent containers, the container carrier including a platform having a top surface, a bottom surface, an outer perimeter, a first container engaging opening positioned above a neck of the first container and having an inner perimeter, a second container engaging opening having an inner perimeter and positioned above a neck of the second container, a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a first portion located toward the first container engaging opening and a second portion located toward the second container engaging opening and separation line between the first portion and the second portion, the separation line comprising a line of weakness along the handle structure; engaging the container carrier on the containers with the first container engaging opening on the neck of the first container and the second container engaging opening on the neck of the second container; and separating the handle structure along the separation line such that the first container has a first single container carrier thereon and the second container has a second single container carrier thereon, the first single container carrier formed by the first container engaging opening and the first portion of the handle structure and the second single container carrier formed by the second container engaging opening and the second portion of the handle structure.

In the foregoing method, the separating step may occur after the engaging step.

The method may include moving the containers to a carrier application location at which the engaging step occurs and the separating step occurs prior to moving the containers away from the carrier application location.

The method may include moving the containers to a carrier application location at which the engaging step occurs and the separating step occurs during movement of the containers away from the carrier application location.

In the foregoing aspect, the separating step may involve moving a separating mechanism downward between the containers and into contact with the handle structure. In such case, the engaging step may involve use of an applicator head that holds the container carrier and that is moved downward toward the containers, the separating mechanism mounted on the applicator head, the applicator head including an opening through which the separating mechanism is moved during the separating step.

In a further aspect, an apparatus for applying a dividable container carrier to a pair of adjacent containers is provided, where the dividable container carrier includes a first container engaging opening, a second container engaging opening, a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a line of weakness therein and along which the dividable container carrier can be separated into two distinct container carriers. The apparatus includes a conveyor, for moving adjacent containers along a path that includes a carrier application station. An applicator head is positioned above the carrier application station for holding and applying a dividable container carrier to a pair of adjacent containers by moving the dividable container carrier downward over the pair of adjacent containers. A separating mechanism is provided for causing the handle structure to separate along the separation line after application of the carrier to the pair of adjacent containers.

In the foregoing aspect, the separator mechanism may be positioned on the applicator head and may be moveable relative to the applicator head. In such case, the separator mechanism may be mounted to move through an opening at a bottom of the applicator head for contacting the dividable container carrier after it has been applied to the set of adjacent containers.

In the foregoing aspect, the separator mechanism may be configured to pull one container of the pair of containers away from the other container of the pair.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top plan view of one embodiment of a dividable two pack carrier;

FIG. 2 shows a perspective view of the carrier of FIG. 1 as applied to a pair of adjacent containers and before separation of the carrier into two single container carriers;

FIG. 3 shows a perspective view of one embodiment of an apparatus for applying the container carriers;

FIG. 4 shows a front elevation view of the apparatus of FIG. 3 with applicator head in an up position;

FIG. 5 shows a front elevation view of the apparatus of FIG. 3 with applicator head in a down position;

FIG. 6 shows an enlarged perspective view of one embodiment of an applicator head;

FIG. 7 shows a front elevation of the head of FIG. 6;

FIG. 8 shows a bottom view of the head of FIG. 6; and

FIGS. 9A and 9B show a prior art two pack carrier.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, one embodiment of a container carrier 10 for use in being applied to a pair of containers 12 and 14 is shown. The illustrated carrier 10 includes a flexible platform 16 having a top surface 18, a bottom surface 20, an outer perimeter 22 and an inner region 24 (interior of the outer perimeter 22). In one implementation the platform is formed of plastic material, has a substantially uniform thickness and is substantially planar, but variations are possible. The inner region includes a container engaging opening 26 and a container engaging opening 28, each having an inner perimeter 30, 32 configured for interacting with a respective rim 34, 36 on the container neck. In the illustrated embodiment each inner perimeter is defined in part by a plurality of inwardly extending tabs 38, 40 that flex as the openings are moved onto the container necks. In one implementation, four sets of diametrically opposed tab pairs are used as shown. Other variations are possible. Once seated below the rims 34 and 36, the openings 26 and 28 engage with the neck and rim securely enough to allow the container to be lifted via the carrier without the carrier sliding off of the container neck.

A longitudinal axis 42 of the carrier extends through a respective center 44, 46 of each of the container engaging openings 26, 28. A handle structure 50 is located between the container engaging openings 26 and 28. In the illustrated embodiment, the handle structure is coupled to the container engaging openings via a generally annular portion 52, 54 of the platform 16 that surrounds each opening and lateral arm pairs 56 and 58 that extend from the annular portions to the handle structure 50. Other variations are possible. The illustrated handle structure includes a central portion 60, and outer side portions 62 and 64, with outer side portion 62 extending from the central portion 60 toward the container engaging opening 26, and with the outer side portion 64 extending from the central portion 60 toward the container engaging opening 28. Thus, the illustrated outer side portions 62 and 64 are diametrically opposed from each other and extend in opposite directions.

The central portion 60 of the handle structure includes a separation line 66 formed therein. In the illustrated embodiment the separation line 66 extends substantially perpendicular to the longitudinal axis 42. The separation line 66 divides the central portion into respective inner portions 68 and 70 that together make up the central portion 60. In the illustrated embodiment, the separation line 66 is formed by a region of connectivity between the inner portions 68 and 70 and a region of disconnectivity between the inner portions 68 and 70. In the particular implementation of regions of connectivity and disconnectivity shown, the region of connectivity is made up of material that connects the inner portions 68 and 70 at spaced apart locations 72 and 74, and the region of disconnectivity is made up of a central gap or spacing 76 between the inner parts 68 and 70 end or outer gaps or spacings 78 and 80 between the inner parts 68 and 70. In the gaps 76, 78 and 80, no material connects the adjacent inner parts 68 and 70. Other configurations of connectivity and disconnectivity are possible (e.g., connecting material at only one location along the separation line or connecting material at more than two locations along the separation line).

As a goal for the breakable carrier is ultimately to be broken along the separation line 76 so that two distinct single container carriers are provided, in one implementation where the separation line has an overall length L_(S), the total length of the connectivity region (in the illustrated case L_(C1)+L_(C2)) can be less than about ten percent of the length L_(S) (e.g., less than about eight percent of L_(S) or less than about five percent of L_(S) or even less than about three percent of L_(S)). This relatively low amount of connectivity facilitates the desired separation and also aids in reducing any bur effect left along the separated edges.

In the illustrated embodiment, a width W_(D) of the region of disconnectivity is substantially uniform as shown and the region of connectivity therefore has the same corresponding width. In this regard, in one implementation the width may be on the order of no more than about ten thousandths of an inch (e.g., between two and eight thousandths of an inch). However, variations are possible. As used herein, the “width” of the region of disconnectivity and the “width” of the region of connectivity each refer to a distance that runs perpendicular to the direction of the separation line (e.g., parallel to the longitudinal axis 42 of the carrier in the illustrated embodiment).

While a separation line 76 formed of regions of connectivity and disconnectivity is shown, it is recognized that other forms of separation lines could be utilized. Generally, a separation line is any line of weakness along the handle structure. For example, a separation could be formed with continuous connectivity but by a region of thinner material (e.g. where a standard thickness of the overall platform is 1 mm, the thickness along the separation line may be 0.10 mm). As another example, a separation line may be formed by pre-stressing the handle structure by bending along the desired location of the separation line to weaken the material along the line. Regardless of the type of separation line used, in certain implementations the separation line may be configured such that pulling the inner portions 68 and 70 away from each other with a force of no more than about eight pounds (e.g., no more than six pounds) along the longitudinal axis (i.e., substantially transverse to the separation line) causes the central portion 60 to separate along the separation line 76. Again, this configuration facilitates the desired separation.

When the central portion 60 is separated along the separation line 76 two single container carriers 80 and 82 are formed. The resulting single container carrier 80 includes container engaging opening 26, annular portion 52, arms 56, inner handle portion 68 and outer side handle portion 62. The resulting single container carrier 82 includes container engaging opening 28, annular portion 54, arms 58, inner handle portion 70 and outer side handle portion 64.

In use, a method of applying the carrier to containers involves positioning a container carrier 10 at a location above adjacent containers (e.g., containers 12 and 14); engaging the container carrier 10 on the containers with the container engaging opening 26 on the neck of one container (e.g., 12) and the container engaging opening 28 on the neck of the other container (e.g., 14) as shown in FIG. 2; and separating the handle structure along the separation line 76 such that the container 12 has a single container carrier 80 thereon and the container 14 has a single container carrier 82 thereon.

One embodiment of an apparatus 100 for carrying out the method is shown in FIGS. 3-8. The apparatus includes a container conveyor 102 for moving containers 104 to a carrier application station 106 and for moving the containers 104 with carriers applied away from the station 106. The exemplary container conveyance direction is shown by arrow 108. The apparatus also includes a carrier supply conveyor 110 on which a series of carrier supply stacks 112 are mounted, such that the carrier supply conveyor can sequentially move a new supply stack into a carrier pick location 114 when a preceding supply stack has been fully used. In the illustrated embodiment, the carrier supply conveyance direction is shown by arrow 116 and the carrier pick station 114 is alongside (e.g., behind in the view of FIG. 4) the carrier application station 106. Each carrier supply stack 112 may be formed by a vertically stacked plurality of the breakable carriers 10 described above with reference to FIGS. 1 and 2.

A container pick and applicator head 120 is moveable between the carrier application station 106 and the carrier pick station 114. In the illustrated embodiment, the container conveyor 102 is horizontal and the carrier supply conveyor 110 angles upward so that each supply stack 112 is also angled upward and toward the carrier application station 106. This arrangement enables the movement of the applicator head 120 between the stations 106 and 114 to be achieved by pivoting the applicator head 120 about a horizontal pivot axis 122. In this regard, the head 120 is pivoted toward the pick station 114 when in a raised position, is moved downward onto the supply stack 112 to pick a container carrier, is raised back up and then pivoted back toward the application station 106. At that point, the applicator head 120 with associated carrier at the bottom thereof is in the position shown in FIG. 4, with the head 120 above a pair of adjacent bottles 104 that have been moved into the application station 106. The applicator head 120 is then moved downwards such that the carrier is pushed over the cap heads of the pair of containers and onto the necks of the container pair as represented by the head position shown in FIG. 5. At this point in time the carrier 10 is applied to the pair of containers, and the next step is to separate the carrier 10 along its separation line 76 into two distinct single container carriers. Thus, at this point in the process and intermediate product is produced in the form of a pair of adjacent containers with respective necks engaging the openings of the carrier, but with carrier of a configuration such that if an attempt was made to lift the containers using the carrier handle 50, the carrier handle would divide along the separation line 66 under the weight of the containers (i.e., the carrier is not capable of being used to lift and carry the pair of containers in the way that the carrier of FIGS. 9A and 9B can be used to lift and carry the pair of containers).

In this regard, reference is made to FIG. 6 that shows an enlarged perspective view the pick and applicator head 120. The head 120 includes a base plate 130, the bottom of which is adapted to hold a carrier 10 as will be described in further detail below. The base plate includes openings 132 and 134 through which the heads of the containers can extend as shown when the carrier is pushed down onto the containers by the downward movement of the head 120. The head base plate 130 also includes an opening 136 through which a carrier separating mechanism 138 can moved downward between the containers and into contact with the handle structure of the carrier 10 to break the carrier along its separation line 76, as best seen in FIG. 7. In the illustrated embodiment the separating mechanism 138 is formed by a wedge-shaped tool that can be moved upward and downward by a shaft 140 of an air cylinder mechanism 142 that is mounted on an intermediate plate 144 of the applicator head 120. Thus, the mechanism 138 moves relative to the rest of the applicator head during the separation step. Both the base plate 130 and intermediate plate 144 extend between side frame portions 146 of the head 120. Other variations are possible, including the use of different types of linear actuators or the use of a separating mechanism that moves in from the side rather than the top.

Thus, in the method carried out by the illustrated apparatus, the step of separating the carrier into two parts occurs immediately after the step of engaging the carrier 10 onto the pair of adjacent containers. Likewise, in the illustrated embodiment, both the engaging step and the separating step occur at the same location (e.g., the station 106) prior to the containers being moved away from the carrier application station 106 by the conveyor 102.

Referring now to FIG. 8, the bottom of applicator head base plate 130 is shown and includes a number of vacuum openings 150 at which a suction or vacuum is applied (e.g., via connection of a vacuum/suction device to connectors 152 that lead to lateral passages within the plate 130). The vacuum holds the container carrier to the bottom of the plate during the pick and move operation.

The subject dividable carrier and applicator head enable the apparatus 100 to be used with both a dividable two pack carrier (e.g., per carrier 10 of FIGS. 1 and 2) and a non-dividable two pack carrier (e.g., similar to carrier 10 but without the separation line 76). When it is desired to use the apparatus 100 to apply non-dividable two pack carriers, the separator mechanism of the applicator head is disabled (e.g., either manually or by a control unit 160 (shown schematically in FIG. 4) of the machine). When it is desired to use the apparatus to apply dividable carriers, the separator mechanism of the applicator head is enabled.

It is to be clearly understood that the above description is intended by way of illustration and example only, is not intended to be taken by way of limitation, and that other changes and modifications are possible. For example, the separating mechanism could take on other forms. In one such alternative, the separating mechanism may be implemented as part of the conveyor 102 (e.g., a mechanism that temporarily holds the following container in place while the leading container is moved away with sufficient force to divide the carrier along its separation line). In this case, the separation occurs during movement of the containers away from the station 106. Still other variations are possible. 

What is claimed is: 1-8. (canceled)
 9. A method of applying carriers to containers utilizing a carrier applicator device, the method comprising: positioning a container carrier at a location above first and second adjacent containers, the container carrier including a platform having a top surface, a bottom surface, an outer perimeter, a first container engaging opening positioned above a neck of the first container and having an inner perimeter, a second container engaging opening having an inner perimeter and positioned above a neck of the second container, a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a first portion located toward the first container engaging opening and a second portion located toward the second container engaging opening and separation line between the first portion and the second portion, the separation line comprising a line of weakness along the handle structure; engaging the container carrier onto the containers with the first container engaging opening on the neck of the first container and the second container engaging opening on the neck of the second container; and separating the handle structure along the separation line utilizing a separating mechanism of the carrier applicator device such that the first container has a first single container carrier thereon and the second container has a second single container carrier thereon, the first single container carrier formed by the first container engaging opening and the first portion of the handle structure and the second single container carrier formed by the second container engaging opening and the second portion of the handle structure.
 10. The method of claim 9 wherein the separating step occurs after the engaging step.
 11. The method of claim 10 wherein the method includes moving the containers to a carrier application location of the carrier applicator device at which the engaging step occurs and the separating step occurs prior to moving the containers away from the carrier application location.
 12. The method of claim 9 wherein the method includes moving the containers to a carrier application location of the carrier applicator device at which the engaging step occurs and the separating step occurs during movement of the containers away from the carrier application location.
 13. The method of claim 9 wherein the separating step involves moving the separating mechanism downward between the containers and into contact with the handle structure.
 14. The method of claim 13 wherein the engaging step involves use of an applicator head that holds the container carrier and that is moved downward toward the containers, the separating mechanism mounted on the applicator head, the applicator head including an opening through which the separating mechanism is moved during the separating step.
 15. The method of claim 14 wherein the separating mechanism comprises a wedge tool that is movable relative to the applicator head via a linear actuator.
 16. The method of claim 15 wherein the linear actuator comprises an air cylinder mechanism. 17-23. (canceled)
 24. A method of applying a carrier to containers, the method comprising: utilizing a carrier in the form of a substantially planar flexible platform having a top surface, a bottom surface, an outer perimeter and an inner region, the inner region including: a first container engaging opening having an inner perimeter configured for interacting with a first container neck rim; a second container engaging opening having an inner perimeter configured for interacting with a second container neck rim, the second container engaging opening spaced from the first container engaging opening; a longitudinal axis of the carrier extending through a center of the first container engaging opening and through a center of the second container engaging opening; a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a central portion, a first outer side portion and a second outer side portion, the first outer side portion extending from the central portion toward the first container engaging opening, the second outer side portion extending from the central portion toward the second container engaging opening, the central portion including a separation line formed therein, the separation line extending substantially perpendicular to the longitudinal axis and between a first inner portion and second inner portion that together make up the central portion, the separation line formed by a region of connectivity between the first inner portion and the second inner portion and a region of disconnectivity between the first inner portion and the second inner portion, engaging the carrier onto first and second containers with the first container engaging opening on a neck of the first container and the second container engaging opening on a neck of the second container; wherein the separation line is weak enough such that the carrier cannot be used to lift and carry the first and second containers without causing the carrier to divide along the separation line; separating the handle structure along the separation line such that when the central portion is separated along the separation line a first single container carrier and second single container carrier are produced, the first single container carrier includes the first container engaging opening engaged on the first container, the second single container carrier includes the second container engaging opening engaged on the second container.
 25. A method of applying carriers to containers utilizing a carrier applicator device, the method comprising: positioning a container carrier at a location above first and second adjacent containers, the container carrier including a platform having a top surface, a bottom surface, an outer perimeter, a first container engaging opening positioned above a neck of the first container and having an inner perimeter, a second container engaging opening having an inner perimeter and positioned above a neck of the second container, a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a first portion located toward the first container engaging opening and a second portion located toward the second container engaging opening and separation line between the first portion and the second portion, the separation line comprising a line of weakness along the handle structure; engaging the container carrier onto the containers with the first container engaging opening on the neck of the first container and the second container engaging opening on the neck of the second container; wherein the separation line is weak enough such that the carrier cannot be used to lift and carry the first and second containers without causing the carrier to divide along the separation line; and separating the handle structure along the separation line utilizing a separating mechanism of the carrier applicator device such that the first container has a first single container carrier thereon and the second container has a second single container carrier thereon, the first single container carrier formed by the first container engaging opening and the first portion of the handle structure and the second single container carrier formed by the second container engaging opening and the second portion of the handle structure.
 26. A method of applying carriers to containers utilizing a carrier applicator device, the method comprising: positioning a container carrier at a location above first and second adjacent containers, the container carrier including a platform having a top surface, a bottom surface, an outer perimeter, a first container engaging opening positioned above a neck of the first container and having an inner perimeter, a second container engaging opening having an inner perimeter and positioned above a neck of the second container, a handle structure located between the first container engaging opening and the second container engaging opening, the handle structure including a first portion located toward the first container engaging opening and a second portion located toward the second container engaging opening and separation line between the first portion and the second portion, the separation line comprising a line of weakness along the handle structure; engaging the container carrier onto the containers with the first container engaging opening on the neck of the first container and the second container engaging opening on the neck of the second container; wherein the separation line is weak enough such that the carrier cannot be used to lift and carry the first and second containers without causing the carrier to divide along the separation line; and separating the handle structure along the separation line such that the first container has a first single container carrier thereon and the second container has a second single container carrier thereon, the first single container carrier formed by the first container engaging opening and the first portion of the handle structure and the second single container carrier formed by the second container engaging opening and the second portion of the handle structure. 